Method of controlling exhaust emission of machine

ABSTRACT

A method of controlling exhaust emission of a machine is provided. The method includes coupling a control unit with an engine of the machine. The method also includes connecting at least one aftertreatment device to the engine of the machine. The at least one aftertreatment device is adapted to control the exhaust emission of the machine. The method further includes receiving, by the control unit, an input signal from the at least one aftertreatment device The method includes identifying the at least one aftertreatment device based on the input signal. The method also includes correlating the input signal with the data stored in the data storage module. The method further includes selecting a mode of operation associated with the at least one aftertreatment device. The method includes controlling the exhaust emission of the machine based on the mode of operation.

TECHNICAL FIELD

The present disclosure relates to a method of controlling exhaustemission of a machine.

BACKGROUND

Machines, such as locomotives, earthmoving vehicles, and automobilesrequire compliance with a variety of emission standards. The emissionstandards vary with regions throughout the world. In order to meet theemission standards, an engine of the machine is tuned or adjusted by acontrol unit. This affects the engine performance and/or fuel economy.Further, the emission standards are met by an aftertreatment device ofthe machine. In order to meet the emission standards of the machine at alocation, the aftertreatment device of the machine is changedaccordingly. The aftertreatment device is controlled by the controlunit, based on the location of the machine. The control unit also needsto be changed with a change in the aftertreatment device.

US Patent Publication 2005/0149248, hereinafter referred to as ‘the '248Publication’, discloses a location-sensitive engine control system. Thelocation-sensitive engine control system includes position locatingsystem (PLS). Further, the PLS interfaces with a control logic which inturn interfaces with an engine control. The PLS relays locationcoordinates to the control logic. The control logic compares thelocation coordinates to an emissions map to determine the emissionrequirements and corresponding engine control settings. The enginecontrol receives the engine control settings from the control logic andadjusts engine parameters to allow the engine to comply with theemission requirements. An antenna or other suitable device for receivingand transmitting information may interface with the control logic toprovide emissions map updates and to allow transmission of the emissionsinformation. However, the '248 publication does not disclose a method tocontrol the aftertreatment device associated with the engine to meet theemission standards at a particular area.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a method of controlling exhaustemission of a machine is provided. The method includes coupling acontrol unit with an engine of the machine. The control unit includes adata storage module for storing data associated with operation of one ormore aftertreatment devices. The method also includes connecting atleast one aftertreatment device to the engine of the machine. The atleast one aftertreatment device is adapted to control the exhaustemission of the machine. The method further includes receiving, by thecontrol unit, an input signal from the at least one aftertreatmentdevice. The method includes identifying the at least one aftertreatmentdevice based on the input signal. The method also includes correlatingthe input signal with the data stored in the data storage module. Themethod further includes selecting a mode of operation associated withthe at least one aftertreatment device. The method includes controllingthe exhaust emission of the machine based on the mode of operation.

Other features and aspects of this disclosure will be apparent from thefollowing description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an exemplary machine, according to the conceptsof the present disclosure;

FIG. 2 is a block diagram of a power supply system for controllingexhaust emissions from the machine of FIG. 1; and

FIG. 3 is a flow chart of a method for controlling the exhaust emissionsfrom the machine of FIG. 1.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments orfeatures, examples of which are illustrated in the accompanyingdrawings. Wherever possible, corresponding or similar reference numberswill be used throughout the drawings to refer to the same orcorresponding parts. Moreover, references to various elements describedherein, are made collectively or individually when there may be morethan one element of the same type. However, such references are merelyexemplary in nature. It may be noted that any reference to elements inthe singular may also he construed to relate to the plural andvice-versa without limiting the scope of the disclosure to the exactnumber or type of such elements unless set forth explicitly in theappended claims.

FIG. 1 illustrates an exemplary machine 10. As illustrated, the machine10 is embodied as a locomotive. The machine 10 may pull cargo containersor passenger cars on a pair of rails 12. Alternatively, the machine 10may include, but not limited to, a marine vessel, an off-highwayvehicle, an on-road vehicle, or any other machine powered by a primemover, such as an internal combustion engine. It should be understoodthat the machine 10 may embody any wheeled or tracked machine associatedwith mining, agriculture, forestry, construction, and any other knownindustrial applications.

Referring to FIG. 1, the machine 10 includes a chassis 14 and anoperator cabin 16 mounted on the chassis 14. The operator cabin 16includes a number of input devices (not shown) for controlling andmonitoring operations of the machine 10. The input devices may include,but not limited to, a push-button and a control lever to control themovement of the machine 10. The machine 10 includes a number of axles18. In the illustrated example, the machine 10 includes six axles. Eachof the axles 18 is associated with a pair of wheels 20. The pair ofwheels 20 may be disposed to support and move the machine 10 on the pairof rails 12.

The machine 10 includes a power supply system 22. The power supplysystem 22 includes an engine 24 and an aftertreatment device 26 coupledto an exhaust conduit (not shown) of the engine 24. The engine 24 ismounted on the chassis 14 of the machine 10. The engine 24 providesdriving power to propel the machine 10. In an example, the engine 24 mayinclude a diesel engine, a gasoline engine, and a gaseous fuel poweredengine such as, a natural gas engine.

The aftertreatment device 26 is connected to the engine 24 for receivingthe exhaust gases flowing out of the engine 24. The aftertreatmentdevice 26 controls exhaust emissions from the machine 10. Moreparticularly, the aftertreatment device 26 removes constituents presentin the exhaust gases, including, but not limited to, NOx, CO, UnburntHydro Carbons emissions, particulates, and/or any other constituentsknown in the art. As shown in FIG. 1, the aftertreatment device 26 issupported on a frame 21 of the machine 10, via an aftertreatmentmounting system 30. The aftertreatment mounting system 30 may include anumber of mounts 32 provided on the frame 21 of the machine 10.

The machine 10 further includes a control unit 28 in electriccommunication with the engine 24 and the aftertreatment device 26. Thecontrol unit 28 determines various operating parameters of the engine 24and the aftertreatment device 26 and, accordingly, controls operationsof the engine 24 and the aftertreatment device 26. Specifically, thecontrol unit 28 is communicably coupled with multiple operating systems,such as a fuel supply system, an air intake system, and an exhaust gasoutlet system of the engine 24.

A sensing unit 29 (shown in FIG. 2) may be disposed in each of theoperating systems of the engine 24 and the aftertreatment device 26. Thecontrol unit 28 may communicate with the sensing unit 29 of each of theoperating systems and the aftertreatment device 26 to receive a signalindicative of the various operating parameters of the engine 24 and theaftertreatment device 26. Upon receiving the signal, the control unit 28determines the various operating parameters associated with the engine24.

Further, it may he contemplated that the control unit 28 may beimplemented as one or more microprocessors, microcomputers, digitalsignal processor, central processing units, state machine, logiccircuitries, and/or any device that is capable of manipulating signalsbased on operational instructions. Among the capabilities mentionedherein, the control unit 28 may receive, transmit, and executecomputer-readable instructions.

Alternatively, the machine 10 may include multiple control units, eachdedicated to communicate with one of the operating systems of the engine24 and the aftertreatment device 26. For example, the engine 24 mayinclude one control unit to control various operations pertaining to theengine 24 and the aftertreatment device 26 may include another controlunit that may be used to control various operations of theaftertreatment device 26. In such a case, the control units of theengine 24 and the aftertreatment device 26 may communicate with eachother.

It may be contemplated that the machine IC) may include a reductantsystem (not shown). The reductant system may include a tank for storinga reductant, such as urea, and a pump (not shown) for supplying thereductant to the aftertreatment device 26 from the tank.

FIG. 2 illustrates a block diagram of the power supply system 22 havingthe engine 24, the aftertreatment device 26, and the control unit 28 ofthe machine 10. The aftertreatment device 26 may include one or moreaftertreatment modules 34. The aftertreatment modules 34 may include,but not limited to, a silencer, a spark arrester, a diesel particulatefilter (DPF), a diesel oxidation catalyst (DOC), a selective catalyticreduction (SCR), a hydro-carbon (HC) dosing system, a catalyticconverter, a fuel burner, or any other aftertreatment modules known inthe art. In one example, the aftertreatment device 26 (see FIG. 1) mayinclude a housing (not shown) coupled to the exhaust conduit of theengine 24. The housing may receive one or more of the aftertreatmentmodules 34 to control the emissions from the engine 24. In such a case,the control unit 28 may communicate with the one or more of theaftertreatment modules 34 to control one or more operations of theaftertreatment device 26.

A cable member 44 connects the sensing unit 29 of the aftertreatmentdevice 26 with the control unit 28. In an example, the cable member 44may be a pigtail. The cable member 44 has a first end 46 connected tothe sensing unit 29 and a second end 48 that is connected to the controlunit 28. The second end 48 is provided with jumper pins (not shown). Anumber of the jumper pins and a configuration of the jumper pins aredefined based on a specification of the aftertreatment device 26. In oneexample, the aftertreatment mounting system 30 may include receptaclesfor connection of the cable member 44 with the sensing unit 29. Thecable member 44 communicates the signal indicative of the operatingparameters of the aftertreatment device 26 with the control unit 28.

For illustration purpose of the present disclosure, additionalaftertreatment devices 26A and 26B are shown in communication with theengine 24. The additional aftertreatment devices 26A and 26B arehereinafter interchangeably referred to as ‘the first additionalaftertreatment device 26A’ and ‘the second additional aftertreatmentdevice 26B’. In one example, the exhaust conduit of the engine 24 may bedesigned to couple with at least one of the aftertreatment device 26,the first additional aftertreatment device 26A, and the secondadditional aftertreatment device 26B. Each of the aftertreatment device26, the first additional aftertreatment device 26A, and the secondadditional aftertreatment device 26B control the emissions of the engine24, based on a statutory requirement. The statutory requirements in oneregion may he vary from the statutory requirements in another region.Accordingly, each of the aftertreatment device 26, the first additionalaftertreatment device 26A, and the second additional aftertreatmentdevice 26B are defined to meet the statutory requirement of a particularregion, where the machine 10 is operating. As such, at least one of theaftertreatment device 26, the first additional aftertreatment device26A, and the second additional aftertreatment device 26B is coupled tothe exhaust conduit of the engine 24 to control the emission based onthe statutory requirements of the region.

In an example, for illustration purpose of the present disclosure, theaftertreatment device 26 may include a silencer (not shown). Also, thefirst additional aftertreatment device 26A may include a DOC (notshown). Further, the second additional aftertreatment device 26B mayinclude a DPF (not shown) and an SCR (not shown). Based on the statutoryrequirements, each of the aftertreatment devices 26, the firstadditional aftertreatment device 26A, and the second additionalaftertreatment device 26B may include aftertreatment modules that aredifferent from those listed above, without limiting the scope of thepresent disclosure.

Each of the first additional aftertreatment device 26A and the secondadditional aftertreatment device 26B includes a first additional sensingunit 29A and a second additional sensing unit 29B, respectively.Further, each of the first and second additional sensing units 29A, 29Bare coupled with a first additional cable member 44A and a secondadditional cable member 44B, respectively, for connecting with thecontrol unit 28. Although, the present disclosure depicts theaftertreatment device 26, the first additional aftertreatment device26A, and the second additional aftertreatment device 26B, it may beunderstood that the exhaust conduit of the engine 24 may be coupled toany other aftertreatment device having one or more aftertreatmentmodules.

As shown in FIG. 2, the control unit 28 includes a sensor module 36. Thesensor module 36 communicably couples with the sensing unit 29 of theaftertreatment device 26. Specifically, the second end 48 of the cablemember 44 is coupled with the control unit 28 such that the signalindicative of the operating parameters of the aftertreatment device 26is communicated with the control unit 28. The configuration of thejumper pins provided in the cable member 44 generates an input signalindicative of various characteristic parameters of the aftertreatmentdevice 26. In an example, the various characteristic parameters mayinclude, but not limited to, a type of the aftertreatment module 34contained in the aftertreatment device 26 and/or dimensionalspecifications of the aftertreatment device 26.

The control unit 28 further includes a processing module 38. Theprocessing module 38 is in communication with the sensor module 36. Theprocessing module 38 receives the input signal from the sensor module 36and determines whether the aftertreatment device 26 is currently coupledto the engine 24. The processing module 38 receives the signalindicative of the various operating parameters of the aftertreatmentdevice 26.

The control unit 28 further includes a data storage module 40. The datastorage module 40 is in communication with the processing module 38. Thedata storage module 40 stores data associated with the operation of theaftertreatment device 26, the first additional aftertreatment device26A, and the second additional aftertreatment device 269. The dataassociated with the operation of the aftertreatment device 26, the firstadditional aftertreatment device 26A and the second additionalaftertreatment device 26B may be a predefined data. The predefined datamay be collected based on lab tests and/or real time simulation of theaftertreatment device 26, the first additional aftertreatment device26A, and the second additional aftertreatment device 26B. The predefineddata may be stored in the data storage module 40 by an operator throughan operator interface of the control unit 28.

The data storage module 40 is also used for storing data associated withthe various operating parameters of the engine 24 and the aftertreatmentdevice 26 that are determined in real time. The data may be stored inthe form of records, look-up tables, and algorithms. The data storagemodule 40 also includes a number of modes of operation associated withthe aftertreatment device 26, the first additional aftertreatment device26A, and the second additional aftertreatment device 269.

Modes of operation may be defined as a set of instructions that allowdesired control of the operating parameters of the aftertreatment device26, based on the statutory requirements. In an example, the mode ofoperation for the aftertreatment device 26 may be defined based on oneor more mathematical relationships between the input signal received bythe processing module 38 and the predefined data associated with theoperation of the aftertreatment device 26. Each mode of operation isassociated with the operation of the engine 24 and the operation of theaftertreatment device 26.

In one implementation, the first additional aftertreatment device 26Amay be coupled to the engine 24 in place of the aftertreatment device26, in order to control the emissions based on the statutoryrequirements. In such a case, the first additional sensing unit 29A ofthe first additional aftertreatment device 26A may be coupled to thefirst additional cable member 44A. Further, a first additional first end464 is connected to the first additional sensing unit 294 and a firstadditional second end 48A of the first additional cable member 44A iscoupled to the control unit 28 such that the signal indicative of theoperating parameters of the first additional aftertreatment device 26Ais communicated with the control unit 28. A configuration of the jumperpins is provided in the first additional cable member 44A to generate aninput signal indicative of various characteristic parameters of thefirst additional aftertreatment device 26A. The processing module 38 incommunication with the sensor module 36 receives the input signal anddetermines whether the first additional aftertreatment device 26A iscurrently coupled to the engine 24.

In another implementation, the second additional aftertreatment device26B may be coupled to the engine 24 in place of the aftertreatmentdevice 26, in order to control the emissions based on the statutoryrequirements. In such a case, the second additional sensing unit 29B ofthe second additional aftertreatment device 26B may be coupled to thesecond additional cable member 44B. Further, a second additional firstend 46B is connected to the second additional sensing unit 29B and asecond additional second end 48B of the second additional cable member44B is coupled to the control unit 28 such that the signal indicative ofthe operating parameters of the second additional aftertreatment device26B is communicated with the control unit 28. A configuration of thejumper pins is provided in the second additional cable member 44B togenerate an input signal indicative of various characteristic parametersof the second additional aftertreatment device 26B. The processingmodule 38 in communication with the sensor module 36 receives the inputsignal and determines whether the second additional aftertreatmentdevice 26B is currently coupled to the engine 24.

The control unit 28 further includes a control module 42. The controlmodule 42 is in communication with the processing module 38. The controlmodule 42 receives the input signal indicative of the aftertreatmentdevice 26, and correlates the input signal with the data stored in thedata storage module 40. Upon correlating the input signal with the datastored in the data storage module 40, the control module 42 selects themode of operation associated with the aftertreatment device 26. Further,the control module 42 generates an output signal indicative of the modeof operation. The control module 42 further communicates this outputsignal with the engine 24 and the aftertreatment device 26 to controlthe exhaust emissions of the machine 10, based on the selected mode ofoperation. Thus, the exhaust emissions of the machine 10 may becontrolled as per the statutory requirements of the region where themachine 10 is operating with the aftertreatment device 26.

Similarly, for the first additional aftertreatment device 26A thecontrol module 42 receives the input signal indicative of the firstadditional aftertreatment device 26A, and correlates the input signalwith the data stored in the data storage module 40. Upon correlating theinput signal with the data stored in the data storage module 40, thecontrol module 42 selects the mode of operation associated with thefirst additional aftertreatment device 26A. Further, the control module42 generates an output signal indicative of the mode of operation. Thecontrol module 42 further communicates this output signal with theengine 24 and the first additional aftertreatment device 26A to controlthe exhaust emissions of the machine 10, based on the selected mode ofoperation. Thus, the exhaust emissions of the machine 10 may becontrolled as per the statutory requirements of the region where themachine 10 is operating with the first additional aftertreatment device26A.

Further, for the second additional aftertreatment device 26B, thecontrol module 42 receives the input signal indicative of the secondadditional aftertreatment device 26B, and correlates the input signalwith the data stored in the data storage module 40. Upon correlating theinput signal with the data stored in the data storage module 40, thecontrol module 42 selects the mode of operation associated with thesecond additional aftertreatment device 26B. Further, the control module42 generates an output signal indicative of the mode of operation. Thecontrol module 42 further communicates this output signal with theengine 24 and the second additional aftertreatment device 26B to controlthe exhaust emission of the machine 10, based on the selected mode ofoperation. Thus, the exhaust emission of the machine 10 may becontrolled as per the statutory requirements of the region where themachine 10 is operating with the second additional aftertreatment device26B.

FIG. 3 illustrates a flowchart of a method 50 for controlling theexhaust emissions of the machine 10. The method 50 will now be explainedin reference to the machine 10 having the aftertreatment device 26.However, it should be noted that the description provided below isequally applicable to the first and second additional aftertreatmentdevices 26A, 26B, without limiting the scope of the present disclosure.

At step 52, the control unit 28 is coupled with the engine 24 of themachine 10. The control unit 28 includes the data storage module 40. Thedata storage module 40 stores data associated with operation of theaftertreatment device 26. At step 54, the aftertreatment device 26 isconnected to the engine 24 of the machine 10. At step 56, the inputsignal from the aftertreatment device 26 is received by the control unit28. The input signal generated by the sensing unit 29 is then conveyedto the control unit 28, via the cable member 44 mounted on theaftertreatment mounting system 30.

At step 58, the control unit 28 identifies the aftertreatment device 26based on the input signal. More particularly, the control unit 28 thatis in communication with the sensing unit 29 receives the input signaland determines the type of the aftertreatment device 26 present based onthe juniper pin configuration on the second end 48 of the cable member44,

At step 60, the input signal is correlated with the data stored in thedata storage module 40. More particularly, the input signal detected bythe control unit 28 is processed by the processing module 38 that is incommunication with the data storage module 40. The input signalindicating the aftertreatment device 26 is then correlated to thepredefined data in the data storage module 40 corresponding to thatparticular aftertreatment device 26.

At step 62, the mode of operation associated with the aftertreatmentdevice 26 is selected. Based on the input signal, the data storagemodule 40 associates the aftertreatment device 26 with the predefinedmode of operation and conveys the mode of operation to the controlmodule 42. At step 64, the exhaust emissions from the machine 10 arecontrolled based on the mode of operation. The control module 42operates the engine 24 based on the mode of operation selected for theaftertreatment device 26, thereby controlling exhaust emissions from themachine 10.

INDUSTRIAL APPLICABILITY

Machines operating in a particularly area are required to meet emissionlimits as per the statutory requirements that are laid down bygovernments of the area. Accordingly, the machine 10 needs to becompliant with the emission limits of the area in which it is operated.Based on the emission limits, different aftertreatment devices areinterchangeably installed on the machine. Different aftertreatmentdevices require different control units for controlling the exhaustemissions.

The present disclosure may find applicability in eliminating theutilization of different control units and to better facilitate in thesensing, fault monitoring, and active aftertreatment controlling. Moreparticularly, the present disclosure relates to the control unit 28 thatis associated with the power supply system 22 of the machine 10. Thecontrol unit 28 ensures that the machine 10 is compliant withincreasingly stringent emissions regulations. Specifically, the controlunit 28 determines a type of the aftertreatment devices 26, 26A, 26Bthat is coupled to the engine 24, and selects the mode of operationbased on the aftertreatment devices 26, 26A, 263, such that the controlunit 28 controls the emissions of the machine 10. By using a singlecontrol unit 28 for the power supply system 22 with different modes ofoperation, an overall complexity associated with interchanging theaftertreatment devices 26, 26A, 26B, may be reduced. Thus, the operatorof the machine 10 doesn't need to change the control unit 28 every timethe aftertreatment device 26 is changed, thereby reducing the machine 10downtime. The control unit 28 described in the present disclosure iscompatible with a number of aftertreatment devices and can be easilyadapted as per the requirement.

While aspects of the present disclosure have been particularly shown anddescribed with reference to the embodiments above, it will be understoodby those skilled in the art that various additional embodiments may becontemplated by the modification of the disclosed machines, systems andmethods without departing from the spirit and scope of what isdisclosed. Such embodiments should be understood to fall within thescope of the present disclosure as determined based upon the claims andany equivalents thereof.

What is claimed is:
 1. A method of controlling exhaust emission of amachine, the method comprising: coupling a control unit with an engineof the machine, wherein the control unit comprises a data storage modulefor storing data associated with operation of one or more aftertreatmentdevices; connecting at least one aftertreatment device to the engine ofthe machine, wherein the at least one aftertreatment device is adaptedto control the exhaust emission of the machine: receiving, by thecontrol unit, an input signal from the at least one aftertreatmentdevice; identifying the at least one aftertreatment device based on theinput signal; correlating the input signal with the data stored in thedata storage module; selecting a mode of operation associated with theat least one aftertreatment device; and controlling the exhaust emissionof the machine based on the mode of operation.